Scrim-reinforced cushion mat for carpet tiles

ABSTRACT

A carpet tile includes a textile top member and a cushion mat that is coupled with the textile top member via a thermoplastic material. The textile top member includes carpet yarns and a backing that is coupled with the carpet yarns so that the backing structurally supports the carpet yarns. The cushion mat includes a polymeric material component having polymer fibers that are randomly oriented and entangled together and a scrim reinforcement that is disposed within the polymeric material component. The scrim reinforcement reinforces and stabilizes the polymeric material component and is entirely covered and concealed by the intermeshed polymer fibers.

BACKGROUND OF THE INVENTION

Carpet tiles offer considerable advantages over rugs or wall to wallcarpeting. For example, the use of carpet tiles for floor coveringprovides a simple installation process and allows removal of individualtiles which have become worn or soiled more than other tiles.Additionally, tiles may be rearranged or replaced to enhance decorativeeffects. Conventional carpet tiles include a pile fabric facing set intoa layer of resilient thermoplastic (including elastomeric) materialwhich is stiffened with a layer of suitable stiffening fibers, such asfiberglass fibers. The tile is generally backed with another layer ofresilient elastomeric or thermoplastic material to which an adhesive maybe applied to set the carpet tile onto the floor.

BRIEF SUMMARY OF THE INVENTION

The embodiments described herein provide a structurally reinforcedcushioned impact-dampening component for carpet tile applications andother applications that utilize a cushioned backing or carrier.According to one aspect a carpet tile includes a textile top member anda cushion mat that is coupled with the textile top member via athermoplastic material. The textile top member includes carpet yarns anda backing that is coupled with the carpet yarns so that the backingstructurally supports the carpet yarns. The cushion mat includes apolymeric material component and a scrim reinforcement that is disposedwithin the polymeric material component. The polymeric materialcomponent includes polymer fibers that are randomly oriented andentangled together and the scrim reinforcement is disposed within thepolymeric material component so that the scrim reinforcement is entirelycovered and concealed by the intermeshed or entangled polymer fibers toprevent the scrim reinforcement from exposure to a user. The scrimreinforcement reinforces and stabilizes the polymeric materialcomponent.

According to another aspect, a method of manufacturing a carpet tileincludes coupling a cushion mat to a textile top member of the carpettile via an adhesive material.

The cushion mat includes a polymeric material component that includespolymer fibers that are randomly oriented and that are entangledtogether and a scrim reinforcement that is disposed within the polymericmaterial component to reinforce and stabilize the polymeric materialcomponent. The scrim reinforcement is disposed within the polymericmaterial component so that the scrim reinforcement is entirely coveredand concealed by the entangled polymer fibers to prevent exposure of thescrim reinforcement to a user.

The textile top member includes carpet yarns and a backing coupled withthe carpet yarns. The adhesive material that couples the cushion mat tothe textile top member penetrates into the entangled polymer fibers ofthe polymeric material component to couple the cushion mat to thetextile top member.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features, aspects, and advantages of the present invention willbe better understood when the following detailed description is readwith reference to the accompanying figures in which like charactersrepresent like parts throughout the figures, wherein:

FIG. 1 is an isometric view of a carpet tile according to embodiments.

FIG. 2 is a detailed side view of the carpet tile of FIG. 1.

FIGS. 3 and 4 illustrate embodiments of a cushion mat of the carpet tileof FIG. 1 in greater detail.

FIG. 5 illustrates a method of manufacturing a carpet tile.

DETAILED DESCRIPTION OF THE INVENTION

The ensuing description provides exemplary embodiments only, and is notintended to limit the scope, applicability, or configuration of thedisclosure. Rather, the ensuing description of the exemplary embodimentswill provide those skilled in the art with an enabling description forimplementing one or more exemplary embodiments. It being understood thatvarious changes may be made in the function and arrangement of elementswithout departing from the spirit and scope of the invention as setforth in the appended claims.

The embodiments described herein provide a structurally reinforcedcushioned impact-dampening component for carpet tile applications andother applications that utilize a cushioned backing or carrier.According to one embodiment, the cushioned backing is a heavy and loftyscrim-reinforced polymeric spunbond mat. When used herein, the term“heavy” refers to a mat that weighs more than 250 grams per squaremeter. The term “lofty” refers to a thick and low density material, suchas a polymeric mat that is at least 1 mm thick and preferably at least 2mm thick and that has a density of less than 15 lb/ft³. Carpet tilepanels are constructed in multiple layers consisting of carpet yarns,various backings, and thermoplastic compounds. Higher-end cushionedcarpet tiles use primarily glass nonwoven mats for strength and rigidityalong with a cushioned impact-dampening component. The cushioned backingor carrier described herein replaces several components in conventionalcarpet tile panels, including the conventional cushioned layer, at leastone of the structural nonwoven layers (i.e., glass fiber mat), andpotentially one of the thermoplastic compound layers. Instead of thesevarious layers, the cushioned backing or carrier includes or consists ofconsolidated polymeric spunbond fibers and a scrim reinforcementcomponent. The cushioned backing or carrier, which is commonly ascrim-reinforced spunbond mat, provides the mechanical strength andstability previously provided by the structural nonwoven layers (i.e.,glass fiber mat), as well as the cushioning effect of the cushion mat.In addition, the loftiness of the scrim-reinforced spunbond mat givesthe cushioned backing or carrier a high capacity for absorption of anycoatings or additives the carpet tile producer may use. The loftinesscharacteristic of the cushioned or backing carrier that provides thehigh capacity for absorption property includes a large void fraction ofthe material, such as a fiber web density (e.g., measured in lb/ft³ org/cm³) that is at least 49% less dense than the polymer material makingup the fibers. The fiber web density may be up to 90% less dense thanthe polymer material making up the fibers. This results in the cushionedbacking or carrier having a void fraction that is at least 51%, whichmeans that the cushioned backing or carrier is at least 51% air or voidspace. The void fraction is typically quite higher than 51% and may beas high as 93%. In a specific embodiment, the void fraction is between85% and 90% and in particular is approximately 89%.

According to one embodiment, the cushioned backing or carrier has athickness of at least 1 millimeters, and more commonly a thickness ofbetween 1 and 8 millimeters. In addition, the cushioned backing orcarrier has a weight of at least 250 grams per square meter (gsm), andmore commonly has a weight of between 250 and 1,000 gsm.

In another embodiment, the cushioned backing or carrier has a thicknessbetween 2 and 6 millimeters and/or a weight of between 400 and 800 gsm.In yet another embodiment, the cushioned backing or carrier has athickness between 3 and 5 millimeters and a weight of between 500 and650 gsm. This cushioned backing or carrier could include a variety ofpolymers, but most commonly includes polyesters and polyolefins, eitherused alone or in combination. In an exemplary embodiment, the cushionedbacking or carrier consists of polyester fibers. Polyester fibers arecomfortable to handle and are bendable and able to recover from a bentstate. The term “bendable” as used herein refers to materials that arenot brittle. For example, the bendable fibers may be contorted, bent,wrapped, compressed, or in similar manners stressed without breaking.Stated differently, the bendable fibers do not break under normal rollhandling and processing during carpet tile manufacturing and future useof the carpet tile. The terms “recoverable” or “spongy” as used hereinrefer to materials that are able to be compressed under weight withoutpermanently deforming, such as a material that returns to its originalthickness once a weight or compression is removed. Specifically, thecushioned backing or carrier should be able to withstand at least 15pounds per square inch (psi) and compress less than 10% of its thicknessat 15 psi. The resistance to compression allows the layer to have aspring or elastic like quality, which enables the cushioned backing orcarrier to recover or return to an original volume after repeatedcompression.

In some instances, a binder may be used to adhere or bond the fibers ofthe cushioned backing or carrier together. When a binder is used, thebinder is typically a formaldehyde-free binder. In other instances, thecushioned backing or carrier does not include a binder that bonds oradheres the fibers of the cushioned backing or carrier together. In suchembodiments, the polymer fibers are mechanically bonded using techniquessuch as needling, which increases the physical entanglement of thepolymer fibers. Needling of the polymer fibers may be preferred in orderto avoid the need to use adhesive or other binders to bond or adhere thefibers together. The application of a binder or adhesive may render thecushioned backing or carrier (i.e., scrim-reinforced polymeric spunbondmat) too dense to absorb the adhesive that is used to adhere thecushioned backing or carrier to the carpet tile. The application of abinder or adhesive may also cause the cushioned backing or carrier to betoo closed off or not sufficiently “spongy”, which would impede theability of the cushioned backing or carrier from properly recovering,thereby negatively impacting the desired cushioning effect of thecushioned backing or carrier. The cushioned backing or carrier should besufficiently “open”, which is defined in terms of the loftiness and highcapacity for absorption described herein. Thus, in order to ensure thatthe cushioned backing or carrier provides a desired cushioning andcomfort effect, mechanical bonding of the cushioned backing or carriermay be preferred.

It should be realized that the description of the cushioned backing orcarrier not including a binder or adhesive as used herein is meant todescribe a state or condition of the cushioned backing or carrier priorto bonding or coupling the cushioned backing or carrier with the carpettile. Subsequent to bonding or coupling the cushioned backing or carrierwith the carpet tile, the cushioned backing or carrier will include someadhesive material (i.e., the thermoplastic material), but the primarypurpose of this material is not to bond or adhere the polymer fiberstogether, but is rather designed and meant to bond or couple thecushioned backing or carrier with a lower surface of the carpet tile. Inaddition, as described herein, the adhesive that is used to attach thecushioned backing or carrier to the carpet tile is only in the topportion of the cushioned backing or carrier and is not disposedthroughout the cushioned backing or carrier. Rather, the bottom portionof the cushioned backing or carrier remains free of any adhesive. Insome embodiments, the portion of the cushioned backing or carrier thatis below the scrim material component remains entirely free of anyadhesive.

The cushioned backing or carrier includes a scrim material that isdisposed within the polymeric material component so that the scrimmaterial is entirely covered and concealed by the intermeshed polymerfibers of the cushioned backing or carrier. The polymeric materialcomponent and the scrim material form a unitary or consolidated materialsince the two materials are integrally formed together, commonly withoutan adhesive or binder material. In contrast, conventional carpet tilesinclude an adhesive or binder layer between the backing and the cushionpad or mat. In contract, the cushioned backing or carrier describedherein functions and acts like a single or unitary product due to thesimultaneous forming of the materials as described herein.

The covering and concealing of the scrim material by the intermeshedpolymer fibers prevents the scrim material from being exposed to thesurrounding environment and to a user that is handling or installing thecarpet tile. Unlike the glass fibers of the scrim material, thepolymeric fibers of the cushioned backing or carrier are not itchy orotherwise irritating or uncomfortable to handle. Since the scrimmaterial is entirely covered and concealed by the polymer fibers, thecushioned backing or carrier is suitable for handling duringinstallation of the carpet tile. In contrast, conventional carpet tiletypically employ multiple thermoplastic layers or films that arerequired to coat and encapsulate a fiberglass backing. Thesethermoplastic layers or films are required to ensure that the fiberglassbacking does not contact a user during handling or installation of thecarpet tile. The instant carpet tile does not require the use of thethermoplastic layers or films since the scrim material is entirelycontained within the cushioned backing or carrier, which encapsulatesthe scrim material and prevents the user from contacting the scrimmaterial. Rather, the user handles and contacts the polymer fibers,which are not itchy or irritating to handle.

The scrim material forms a reinforcement layer within the cushionedbacking or carrier and thus, the scrim material may also be referred toherein as a scrim reinforcement. The scrim reinforcement is configuredto mechanically reinforce and stabilize the cushioned backing orcarrier. Dimensional stability is important in a carpet tile.Dimensional stability is the ability of a carpet tile to lie flat andremain flat and square on a floor surface under conditions of normaluse. The industry standard Aachen DIN STD 54318 test is used todetermine the dimensional stability. The scrim reinforcement issufficient to stabilize the carpet tile to impart the requireddimensional stability.

The scrim reinforcement is typically made of glass fibers that areformed or arranged in a grid pattern, although other non-glass fibersmay be used in place of or in addition to the glass fibers. The scrimreinforcement is introduced into the cushioned backing or carrier duringproduction of the cushioned backing or carrier. The mechanical bonding(e.g., needling) of the polymer fibers is sufficient to entrap andattach the scrim reinforcement to the cushioned backing or carrier. Thescrim reinforcement may be located in the middle of the cushionedbacking or carrier so that there is an equal weight or density of thepolymer fibers both above and below the scrim reinforcement. In otherembodiments, the scrim reinforcement may be shifted toward an uppersurface of the cushioned backing or carrier to tailor the strength andcushioning ability of the cushioned backing or carrier. A bottom surfaceof the cushioned backing or carrier is formed of the polymer fibers,which provide a relatively smooth and finished surface for facing thefloor.

In some instances, the cushioned backing or carrier does not havesufficient strength and stability without the incorporation of the scrimreinforcement within the cushioned backing or carrier. In otherinstances, the cushioned backing or carrier may not include a scrimreinforcement. Rather, the cushioned backing or carrier may employcoarse polymer fibers and have a more dense configuration, which mayallow the cushioned backing or carrier to be sufficiently strong andstable without the use of a scrim reinforcement.

Having described various embodiments generally, additional aspects andfeatures of the carpet tile and cushioned backing or carrier will bemore evident with reference to the description of the various drawingsprovided herein below.

FIGS. 1 and 2 illustrate an embodiment of a carpet tile 100. The carpettile 100 is shown as being square-shaped, which is a common shape ofcarpet tiles. However, as a person of skill in the art will readilyrecognize, the carpet tile 100 may be cut or otherwise formed in anydesired shape and/or can be sized to match any desired application.Additionally, the textile top member may be formed from any fabric orother textile material to fit the needs or aesthetics of a particularapplication. Carpet tile 100 includes a textile top member 101 that ispositioned atop a cushioned backing or carrier 110. For ease indescribing the embodiments, the cushioned backing or carrier will bereferred to hereinafter as a cushion mat 110.

The textile top member includes carpet yarns 102 that are attached to abacking 104. The carpet yarns 102 may be formed from any fabric or othertextile material to fit the needs or aesthetics of a particularapplication, and may specifically include tufted carpet yarns, pilefabric yarns, polyester fibers, nylon fibers, polyolefin fibers, and thelike. The carpet yarns 102, such as a pile fabric layer or other fabriclayer, serves as an exposed top surface of the carpet tile. The carpetyarns 102 are typically hooked through the backing 104 and secured orcoupled to the back of the backing 104. Coupling the carpet yarns 102 tothe backing 104 typically involves using various adhesives, such as hotmelt materials. The backing 104 is typically a woven or nonwovenmaterial that is often made of polymer, cellulose fibers, or acombination of these. The backing 104 structurally supports andreinforces the textile top member 101. A pre-coat 106 is typicallypositioned on the backing 104 to lock the carpet yarns 102 in place. Thepre-coat may be a latex based material or any other suitable material.In some instances, the pre-coat may be a hot melt adhesive that may bedesigned to permit lamination between the textile top member 101 and thecushion mat 110. The textile top member 101 and/or carpet tile 100 mayinclude additional materials, such as flame retardants and the like,depending on the end use of the carpet tile 100.

The cushion mat 110 is attached to the textile top member 101 via athermoplastic material 108, such as a thermoplastic elastomer and/or aplastisol material.

Exemplary thermoplastic materials 108 that may be used to couple thecushion mat 110 with the textile top member 101 include polymers orcopolymers of latex, vinyl chlorides, polyolefins, polyurethanes,acrylates, acrylics, or styrenes. The thermoplastic material 108typically adheres to the precoat layer 106 and penetrates into thecushion mat 110. The amount or degree of penetration of thethermoplastic material 108 into the cushion mat 110, may be controlledas described below. The cushion mat 110 is designed to be a loftymaterial that provides impact dampening for the carpet tile 100. Thecushion mat 110 is also strong enough to contribute to the structuralintegrity of the finished carpet tile 100 in the same manner asconventional backings.

The cushion mat 110 is a multi-function unitary or consolidated materialthat provides the above described cushioning and structural features.The consolidated cushion mat 110 replaces multiple layers inconventional carpet tiles, such as a separate cushioning mat, secondarybacking, and thermoplastic coating layer. The secondary backing materialthat is used in conventional carpet tiles is typically a glass nonwoven.The secondary backing material is a required layer that providesdimensional stability to the carpet tile. The secondary backing iscoated with a thermoplastic coating so that the glass fibers are notexposed to a user, which may cause irritation and/or itch. Thethermoplastic coating is typically applied as a coating to the top andbottom of the secondary backing to ensure that the thermoplasticmaterial fully surrounds and encapsulate the glass fibers. Thethermoplastic coating is also used to attach the secondary backing tothe cushion mat so that the secondary backing forms a separate layeratop the cushion mat. The cushion mat can be either a foamed polymericmaterial, such as polyurethane or a felt material. The cushion mat maycontain additional additives, such as fire retardants and the like.

In contrast to these various layers, the cushion mat 110 describedherein is a unitary or consolidated material that is able to provideboth cushioning or impact dampening and structural strength. The termunitary or consolidated means that the components of the cushion mat 110are formed in a manner that results in the cushion mat 110 functioningas a single material. The cushioning is provided by a polymeric materialcomponent 114 that includes polymer fibers that are randomly orientedand entangled together. The polymeric material component 114 istypically a spunbond material that is lofty and recoverable, meaningthat the material is an elastically compressible material that is ableto rebound or recover from a compressed state. The polymer fibers of thepolymeric material component 114 may comprise or consist of polyesters,polyolefins, or a combination of polyesters and polyolefins.

The structural strength is provided by a scrim reinforcement 112 that isdisposed within the polymeric material component 114 so that the scrimreinforcement 112 is entirely covered and concealed by the intermeshedor entangled polymer fibers. The positioning of the scrim reinforcement112 within the polymeric material component 114 prevents the scrimreinforcement 112 from being exposed to the surrounding environment, andin particular to a user that may be handling or installing the cushionmat 110 or carpet tile 100. The scrim reinforcement 112 is a fiber matthat includes fibers or rovings that are typically orientedperpendicularly. The fibers or rovings may be made of various fibers,but are commonly made of glass fibers. The scrim reinforcement 112mechanically reinforces and stabilizes the carpet tile.

The cushion mat 110 typically has a thickness between 1 and 8millimeters. In a more specific embodiment, the cushion mat 110 has athickness of between 2 and 6 millimeters. In yet another specificembodiment, the cushion mat 110 has a thickness of between 3 and 5millimeters.

The density of the cushion mat 110 may vary depending on the endapplication of the carpet tile 100. For example, the cushion mat 110 maybe constructed to be relatively thin and dense or thick and open. Theformer construction may allow the cushion mat 110 to hold its shapebetter and may be suited for high use or traffic areas while the latterconstruction may be preferred for increased cushioning and comfort dueto its loftier design. The cushion mat 110 typically has a weight ofbetween 250 and 1,000 grams per square meter (gsm), and more commonlyhas a weight of between 400 and 800 gsm. In s specific embodiment, thecushion mat 110 has a weight of between 500 and 650 gsm.

In some embodiments, a binder may be used to adhere or bond the polymerfibers of the polymeric material component 114 together. In otherembodiments, the polymeric material component 114 does not include abinder that bonds or adheres the polymer fibers together. Rather, thepolymer fibers are mechanically bonded using techniques such asneedling, which increases the physical entanglement of the polymerfibers. The polymer fibers are mechanically bonded (e.g., needled)together in a manner that ensures that the polymeric material component114 and scrim reinforcement 112 are mechanically bonded or interlockedsuch that the cushion mat 110 does not include an adhesive material thatbonds the polymeric material component 114 and scrim reinforcement 112together.

Mechanical bonding of the polymer fibers is typically preferred to avoidthe need to use adhesive or other binders that may negatively impactdesired properties of the cushion mat 110. For example, the use ofadhesives may render the cushion mat 110 too dense to absorb thethermoplastic material that bonds the cushion mat 110 to the textile topmember 101. The use of adhesives may also cause the cushion mat 110 tobe too closed off or not sufficiently “spongy”, which would impede theability of the cushion mat 110 from being elastically compressed,thereby negatively impacting the desired cushioning and dampeningeffect. Stated differently, the use of an adhesive may make the cushionmat 110 too rigid to be effectively used in cushioning the carpet tile100. If the cushion mat 110 is free of a binder or adhesive, the polymerfibers may move relative to one another in a manner that allows thefibers to more elastically recover from a compressed stated, therebyincreasing the desired cushioning and dampening effect of the cushionmat 110.

As briefly described above, the cushion mat 110 is relatively porous orhas a degree of openness that allows the cushion mat 110 to absorb athermoplastic compound or material 108 that is used to bond or adherethe cushion mat 110 to the textile top member 101. Since thethermoplastic material 108 absorbs into the cushion mat 110 to a degree,the cushion mat 110 will include some amount of an adhesive materialafter the cushion mat 110 is attached to the textile top member 101.However, in embodiments in which the cushion mat 110 does not include abinder or adhesive, the cushion mat 110 does not include a binder oradhesive that is separate from the thermoplastic material 108 that bondsthe individual polymer fibers together. Thus, even though thethermoplastic material 108 absorbs into the cushion mat 110 to a degree,many or most of the polymer fibers, and a substantial portion or volumeof the cushion mat 110, remains free of a binder or adhesive. Forexample, as described below, the thermoplastic material 108 typicallydoes not penetrate into the cushion mat 110 below the scrimreinforcement 112 and thus, even though some of the thermoplasticmaterial 108 is absorbed into the cushion mat 110, the portion or volumeof the cushion mat 110 below the scrim reinforcement remains free of thethermoplastic material 108 and free of any other binder or adhesivematerials.

In some embodiments, the thermoplastic material may absorb into thecushion mat 110 and may fully surround and encapsulate the scrimreinforcement 112 that is disposed within the cushion mat. In suchembodiments, the scrim reinforcement 112 may be both positioned withinthe cushion mat 110 and fully encapsulated and covered by thethermoplastic material 108. The full encapsulation of the scrimreinforcement 112 by the thermoplastic material may aid in reinforcingthe carpet tile.

In some embodiments, the polymer fibers of the polymeric materialcomponent 114 comprise or consist of polymer fibers having an averagefiber diameter of between 0.5 and 10 denier, and more commonly compriseor consist of polymer fibers having an average fiber diameter of between1 and 10 denier. In more specific embodiments, the polymer fiberscomprise or consist of polymer fibers having an average fiber diameterof between 2.5 and 9 denier and most commonly comprise or consist ofpolymer fibers having an average fiber diameter of between 4 and 9denier. The larger fiber diameters typically yield stronger fibers thatare more resistant to compression and able to handle more weight and/orrecover better to compression events. Polymer fibers, and in particularpolyester fibers, demonstrate good abilities in resisting compressionand handling weight.

In some embodiments, the scrim reinforcement comprises or consists ofglass fibers having an average fiber diameter between about 10 and 90tex and more commonly comprises or consists of glass fibers having anaverage fiber diameter between about 10 and 50 tex or between 50 and 90tex. In a specific embodiment, the scrim reinforcement comprises orconsists of glass fibers having an average fiber diameter between about30 and 36 tex or between 65 and 71 tex. Thicker glass fibers typicallyresult in greater tensile strength and may be employed when strongerscrim reinforcement materials are required.

Referring now to FIGS. 3 and 4, embodiments of the cushion mat 110 areillustrated in greater detail. Specifically, FIGS. 3 and 4 illustratehow the position of the scrim reinforcement 112 within the polymericmaterial component 114 may be adjusted to achieve a desired effect inthe carpet tile 100. In FIG. 3, the scrim reinforcement 112 is roughlycentered within the polymeric material component 114 so that a firstportion or volume 122 of polymer fibers that is positioned above thescrim reinforcement 112 is roughly equal to a second portion or volume124 of polymer fibers that is positioned below the scrim reinforcement112. The centered configuration of the scrim reinforcement 112 may bedesired when increased bonding between the cushion mat 110 and textiletop member 101 is desired. For example, since the thermoplastic material108 typically penetrates into the cushion mat 110 up to the scrimreinforcement 112, but not beyond the scrim reinforcement, the centerpositioning of the scrim reinforcement 112 allows additionalthermoplastic material 108 to absorb into the cushion mat 110, whichincreases the bond between the cushion mat 110 and the textile topmember 101. The increased penetration of the thermoplastic material 108into the cushion mat 110 may render the cushion mat 110 more rigid andmore resistant to wear. Thus, the center positioning of the scrimreinforcement 112 may be preferred when the carpet tile 100 is used inhigh traffic areas. The non-centered positioned of the scrimreinforcement 112 may result in a more loftier and cushioning mat 110,which may be preferred in areas where increased comfort is desired.

In contrast, in FIG. 4, the scrim reinforcement 112 is non-centeredwithin the polymeric material component 114 so that the scrimreinforcement is positioned closer to a top surface of the polymericmaterial component 114 than a bottom surface of the polymeric materialcomponent 114. Since the scrim reinforcement 112 is not centered withinthe polymeric material component 114, the first portion or volume 122 ofpolymer fibers that is positioned above the scrim reinforcement 112 isless than the second portion or volume 124 of polymer fibers that ispositioned below the scrim reinforcement 112. The non-centered scrimreinforcement 112 may be preferred when increased cushioning ordampening is preferred. For example, the cushioning or dampening effectof the cushion mat 110 may be provided mainly from the second portion orvolume 124 of polymer fibers. Since the second portion or volume 124 ofpolymer fibers is greater when the scrim reinforcement 112 is notcentered, the cushioning or dampening properties of the cushion mat 110may be enhanced. In addition, the thermoplastic material 108 typicallydoes not penetrate into the polymeric material component 114 below thescrim reinforcement 112 and thus, the second portion or volume 124 ofpolymer fibers are not constrained or restricted in their movement andresponse by the thermoplastic material 108. As such, the polymer fibersin the second portion or volume 124 may be more responsive as thecushion mat is compressed, which may enhance the desired cushioning anddampening properties of the cushion mat 110.

In some embodiments, the scrim reinforcement 112 is positioned withinthe polymeric material component 114 so that at least 65% or 70% of thepolymer fibers are positioned below the scrim reinforcement 112 and atleast 5% of the polymer fibers are positioned above the scrimreinforcement 112. Stated differently, the scrim reinforcement 112 maybe positioned within the polymeric material component 114 so that thesecond portion or volume 124 is at least 65% or 70% of the volume of thecushion mat 110 and the first portion or volume 122 is at least 5% ofthe volume of the cushion mat 110. In other embodiments, the scrimreinforcement 112 is positioned within the polymeric material component114 so that at least 60-95% of the polymer fibers are positioned belowthe scrim reinforcement 112 and so that at least 5-40% of the polymerfibers are positioned above the scrim reinforcement 112. In a morespecific embodiment, the scrim reinforcement 112 is positioned withinthe polymeric material component 114 so that at least 65-90% of thepolymer fibers are positioned below the scrim reinforcement 112 and sothat at least 10-35% of the polymer fibers are positioned above thescrim reinforcement 112. In yet another specific embodiment, the scrimreinforcement 112 is positioned within the polymeric material component114 so that at least 65-75% of the polymer fibers are positioned belowthe scrim reinforcement 112 and so that at least 25-35% of the polymerfibers are positioned above the scrim reinforcement 112.

The scrim reinforcement 112 may be positioned within the polymericmaterial component 114 during formation of the polymeric materialcomponent 114. Stated differently, incorporation of the scrimreinforcement 112 into the polymeric material component 114 may beachieved in a single step or process so that the individual materialsare not separately formed and then combined in a later stage or process(i.e., separately made and then bonded together). Rather, the materialsmay be formed simultaneously, which results in a cushion mat 110 thatfunctions and behaves as a unitary or single component in terms ofstructure and integrity despite having different fiber compositionsand/or materials. To form the materials simultaneously, the secondportion or volume 124 may be formed, via spunbonding or another process,and the scrim reinforcement 112 may be laid atop the second portion orvolume 124 while the first portion or volume 122 is being formed, viaspunbonding or another process. The various materials may then bemechanically bonded, such as via needling to make the cushion mat 110function and behave as a single or unitary product.

As described herein, the thermoplastic material 108 typically penetratesinto the polymeric material component 114 to couple the cushion mat 110to the textile top member 101. The thermoplastic material 108 is able topenetrate into the polymeric material component 114 due to apermeability of the polymeric material component 114. In contrast, inconventional carpet tile the adhesive material typically rests atop asecondary backing or only penetrates a negligible amount into thematerials. The adhesive material typically coats the materials orpenetrates into the materials just enough to adhere the two materials.The penetration of the thermoplastic material 108 into the polymericmaterial component 114 in the instant embodiments enhances the bondingbetween the cushion mat 110 and the textile top member 101.

In the instant embodiments, the scrim reinforcement 112 is typicallyconfigured to control penetration of the thermoplastic material 108 intothe polymeric material component 114 so that the thermoplastic material108 is able to penetrate into the polymeric material component 114 up tothe scrim reinforcement 112, but not beyond the scrim reinforcement 112.Limiting the penetration of the thermoplastic material 108 into thepolymeric material component 114 helps ensure that a desired cushioningeffect is achieved. The depth or degree of penetration of thethermoplastic material 108 into the cushion mat 110 may be controlled byvarying the position of the scrim reinforcement 112 within the polymericmaterial component 114. In embodiments in which the cushion mat 110 isfree of a binder or adhesive material, the cushion mat 110 does notinclude the thermoplastic material 108 or any other binder or adhesivematerials below the scrim reinforcement 112.

Referring now to FIG. 5, illustrated is a method 200 of manufacturing acarpet tile. At block 202, a cushion mat is provided. As describedherein, the cushion mat includes a polymeric material component havingpolymer fibers that are randomly oriented and that are entangledtogether and a scrim reinforcement that is disposed within the polymericmaterial component to mechanically reinforce and stabilize the polymericmaterial component. The scrim reinforcement is disposed within thepolymeric material component so that the scrim reinforcement is entirelycovered and concealed by the entangled and intermeshed polymer fibers,which prevents exposure of the scrim reinforcement to a user and/or thesurrounding environment. At block 204, the cushion mat is coupled to atextile top member of the carpet tile via an adhesive material. Asdescribed herein, the textile top member includes carpet yarns and abacking that is coupled with the carpet yarns. The adhesive materialpenetrates into the entangled polymer fibers of the polymeric materialcomponent to couple the cushion mat to a textile top member of thecarpet tile. The cushion mat may have a thickness between 1 and 8millimeters and may have a density of between 250 and 1,000 grams persquare meter (gsm).

In some embodiments, the adhesive material that penetrates into theentangled polymer fibers of the polymeric material component is athermoplastic material or a plastisol. The polymer fibers of thepolymeric material component may include or consist of polyesters,polyolefins, or a combination of polyesters and polyolefins. The polymerfibers of the polymeric material component may be mechanically needledtogether in a manner that ensures that the polymeric material componentand scrim reinforcement are mechanically bonded so that the cushion matdoes not include an adhesive material that bonds the polymer fibers andscrim reinforcement together.

In some embodiments, the scrim reinforcement is non-centered within thepolymeric material component so that the scrim reinforcement ispositioned closer to a top surface of the polymeric material componentthan a bottom surface of the polymeric material component. For example,the scrim reinforcement may be positioned within the polymeric materialcomponent so that at least 60% of the polymeric material of thepolymeric material component is positioned below the scrim reinforcementand at least 5% of the polymeric material of the polymeric materialcomponent is positioned above the scrim reinforcement. In a morespecific embodiment, the scrim reinforcement may be positioned withinthe polymeric material component so that at least 70% of the polymericmaterial of the polymeric material component is positioned below thescrim reinforcement and at least 10% of the polymeric material of thepolymeric material component is positioned above the scrimreinforcement.

Having described several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theinvention. Additionally, a number of well-known processes and elementshave not been described in order to avoid unnecessarily obscuring thepresent invention. Accordingly, the above description should not betaken as limiting the scope of the invention.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassed.The upper and lower limits of these smaller ranges may independently beincluded or excluded in the range, and each range where either, neitheror both limits are included in the smaller ranges is also encompassedwithin the invention, subject to any specifically excluded limit in thestated range. Where the stated range includes one or both of the limits,ranges excluding either or both of those included limits are alsoincluded.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural referents unless the context clearly dictatesotherwise. Thus, for example, reference to “a process” includes aplurality of such processes and reference to “the device” includesreference to one or more devices and equivalents thereof known to thoseskilled in the art, and so forth.

Also, the words “comprise,” “comprising,” “include,” “including,” and“includes” when used in this specification and in the following claimsare intended to specify the presence of stated features, integers,components, or steps, but they do not preclude the presence or additionof one or more other features, integers, components, steps, acts, orgroups.

What is claimed is:
 1. A carpet tile comprising: a textile top memberincluding: carpet yarns; and a backing that is coupled with the carpetyarns so that the backing structurally supports the carpet yarns; and acushion mat coupled with the textile top member via a thermoplasticmaterial, the cushion mat comprising: a polymeric material componentcomprising polymer fibers that are randomly oriented and entangledtogether; and a scrim reinforcement that is disposed within thepolymeric material component so that the scrim reinforcement is entirelycovered and concealed by the entangled polymer fibers to prevent thescrim reinforcement from exposure to a user, the scrim reinforcementbeing configured to mechanically reinforce and stabilize the polymericmaterial component and carpet tile.
 2. The carpet tile of claim 1,wherein the cushion mat has a thickness between 1 and 8 millimeters. 3.The carpet tile of claim 1, wherein the cushion mat has a weight ofbetween 250 and 1,000 grams per square meter (gsm).
 4. The carpet tileof claim 1, wherein the polymer fibers of the polymeric materialcomponent comprises polyesters, polyolefins, or a combination ofpolyesters and polyolefins.
 5. The carpet tile of claim 1, wherein thecushion mat does not include a binder that adhesively bonds the polymerfibers together.
 6. The carpet tile of claim 1, wherein the scrimreinforcement: consists of glass fibers having an average fiber diameterbetween about 10 and 90 tex.
 7. The carpet tile of claim 1, wherein thescrim reinforcement is non-centered within the polymeric materialcomponent so that the scrim reinforcement is positioned closer to anupper surface of the polymeric material component than a lower surfaceof the polymeric material component.
 8. The carpet tile of claim 7,wherein the scrim reinforcement is positioned within the polymericmaterial component so that at least 60% of the polymeric material of thepolymeric material component is positioned below the scrim reinforcementand at least 5% of the polymeric material of the polymeric materialcomponent is positioned above the scrim reinforcement.
 9. The carpettile of claim 7, wherein the thermoplastic material penetrates into thepolymeric material component to couple the cushion mat with the textiletop member, and wherein the scrim reinforcement is configured to controlpenetration of the thermoplastic material into the polymeric materialcomponent so that the thermoplastic material penetrates into thepolymeric material component up to the scrim reinforcement, but notbeyond the scrim reinforcement.
 10. The carpet tile of claim 9, whereinthe cushion mat does not include any binder or adhesive materials belowthe scrim reinforcement.
 11. The carpet tile of claim 1, wherein thepolymeric material component comprises polymer fibers having an averagefiber diameter of between 0.5 and 10 denier.
 12. The carpet tile ofclaim 11, wherein the polymer fibers are mechanically needled togetherin a manner that ensures that the polymeric material component and scrimreinforcement are mechanically bonded such that the cushion mat does notinclude an adhesive material that bonds the polymer fibers and scrimreinforcement together.
 13. A method of manufacturing a carpet tilecomprising: providing a cushion mat comprising: a polymeric materialcomponent comprising polymer fibers that are randomly oriented and thatare entangled together; and a scrim reinforcement that is disposedwithin the polymeric material component to mechanically reinforce andstabilize the polymeric material component, the scrim reinforcementbeing disposed within the polymeric material component so that the scrimreinforcement is entirely covered and concealed by the entangled polymerfibers to prevent exposure of the scrim reinforcement to a user; andcoupling the cushion mat to a textile top member of the carpet tile viaan adhesive material, the textile top member comprising: carpet yarns;and a backing coupled with the carpet yarns; wherein the adhesivematerial penetrates into the entangled polymer fibers of the polymericmaterial component to couple the cushion mat to the textile top memberof the carpet tile.
 14. The method of claim 13, wherein the adhesivematerial that penetrates into the entangled polymer fibers of thepolymeric material component comprises a thermoplastic material or aplastisol.
 15. The method of claim 13, wherein the polymer fibers of thepolymeric material component comprises polyesters, polyolefins, or acombination of polyesters and polyolefins.
 16. The method of claim 13,wherein the polymer fibers of the polymeric material component aremechanically needled together in a manner that ensures that thepolymeric material component and scrim reinforcement are mechanicallybonded such that the cushion mat does not include an adhesive materialthat bonds the polymer fibers and scrim reinforcement together.
 17. Themethod of claim 13, wherein the scrim reinforcement is non-centeredwithin the polymeric material component so that the scrim reinforcementis positioned closer to a top surface of the polymeric materialcomponent than a bottom surface of the polymeric material component. 18.The method of claim 17, wherein the scrim reinforcement is positionedwithin the polymeric material component so that at least 60% of thepolymeric material of the polymeric material component is positionedbelow the scrim reinforcement and at least 5% of the polymeric materialof the polymeric material component is positioned above the scrimreinforcement.
 19. The method of claim 13, wherein the cushion mat has athickness between 1 and 8 millimeters.
 20. The method of claim 13,wherein the cushion mat has a weight of between 250 and 1,000 grams persquare meter (gsm).